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LUKOIL

Construction of a Gas Processing Plant as part of the Kandym Project in Uzbekistan

Project Objectives

  1. To provide the Kandym Gas Processing Plant (the largest production site of LUKOIL PJSC in Central Asia) with technical and integration solutions allowing for the introduction and deployment of advanced enterprise management practices, as well as automation of the main business processes and processing chains. Undertaking this task entailed the development of a concept for building a unified software and hardware environment enabling the running of IT, security and radio communication systems, telephone communications, as well as production and dispatch connection systems designed for safe and efficient operation of the site.
  2. Development functionality enabling the integration of engineering information systems and security measures with the unified enterprise management system, automation systems, and other IT and communication services on site and within the Customer’s infrastructure in general.   
  3. To provide production enterprise personnel and all business processes with high-quality, reliable engineering information systems and security measures: radio communication at production facilities, video surveillance systems for monitoring production processes and a transport network ensuring the effectiveness of information services.

The project for the construction of the Kandym Gas Processing Plant implemented under the Agreement between LUKOIL and the Republic of Uzbekistan, is one of the largest investment projects in the Republic of Uzbekistan. Planned as part of the project  is a natural gas collection system, gas transmission plant, administrative building, maintenance areas and other facilities, as well as an autonomous residential complex for 1,150 people in the Kandym field area. The project also includes about 500 km of technological and field pipelines, 281 km of roads, water lines, 272 km of power lines, and 50 km of railway access.

With a production capacity of 8.1 billion cubic meters of gas per year, the plant processes hydrogen sulfide gas for the production of purified natural fuel, stable gas condensate, and block and granulated sulfur.

The ITPS Group of Companies has been involved in the project from its inception and together with ENTER Engineering and the Hyundai Engineering Company developed the IT and security system architecture.

The scope of the project included development of IT systems and security systems for the Kandym Gas Processing Plant, a facility with the production capacity of 8 billion cubic meters of gas per year. The plant consists of two technological lines – each with a 4 billion cubic-meter capacity – facilities for external electricity and water supply, a gas collection system and export pipeline, a field camp, fire station, etc.

As part of the conceptual design, the foundation was laid for the creation of an integrated IT system, including IT infrastructure and communication systems as well as an integrated process control system and MES, and technical security measures.

The ongoing cooperation of ITPS with all project stakeholders, combined with an integrated approach to its implementation, ensured construction of a high-quality IT infrastructure as part of the investment program. The timeline for the project’s implementation was limited. Consequently, this required simultaneous execution of various tasks, such as for example, the supply of equipment  as early as the system design stage.

CHALLENGES AND RISKS

The complexity of the project was largely  due to the climatic conditions of the area: the Kandym fields are located on a desert plain 90% of which is sand. The climate is distinctly continental with hot and dry summers and harsh winters. In addition, water resources are limited. This required a complex infrastructural setup to ensure the stable functioning of IT infrastructure and the uninterrupted operation of equipment installed both inside the premises of the Kandym Gas Processing Plant, and outside, on the territory of the facility, where sandstorms are frequent.

In order to effectively use the implemented systems, ITPS specialists were present on site during trial operation, when they continued to provide training and consulting for customer employees, as well as additional equipment adjustments in accordance with the customer’s requirements.

Implementation of a complex, large-scale high-tech project was made possible thanks to the coordinated work of a big team of professionals which included highly qualified specialists not only from Russia, but also from Uzbekistan, the CIS countries, and world leaders from the IT industry. Construction of the plant was the  fruit of their cooperation, based on advanced technology and automated solutions taking into account today’s occupational safety requirements and labour protection, designed to make the operation of facilities at the fields as efficient as possible.

Result

  1. Integration of the IT infrastructure at the Kandym Gas Processing Plant: from IT infrastructure and communication systems to an integrated process control system and MES, as well as technical security measures. ITPS provided integration of the physical transport system architecture at all the new project sites, with subsystems built by different IT contractors, developed conceptual design and working documentation, conducted integration tests, commissioning and provided production personnel with high-quality VHF radio communications based on the solutions from the largest European aerospace corporation Airbus Defense & Space. In the end the customer received a reliable modern set of systems (more than ten installed modules using equipment and software from the reputable provider). The plant fully adheres to IT infrastructure best practices for large industrial enterprises. IT services ensure trouble-free online operation 24/7.
  2. The IT infrastructure created at the gas processing plant and other facilities of the Kandym field is the basis for the digitalization of the company's assets. This innovative approach to the management of extracting enterprises includes the introduction of a set of modern technical, technological and organizational solutions to ensure interaction of all elements and subjects of production management in order to continuously enhance its performance indicators. According to the experience of the world’s major oil and gas producing enterprises, the main result of the digitalization of fields is the reduction of losses and the increase in production throughout the entire life cycle of field development.
  3. The project was completed on schedule, in a short time frame - despite the remote location of the facility and the climatic conditions - and was delivered on budget and in accordance with international quality standards. When creating the telecommunications and IT infrastructures of the facility, the ITPS Group of Companies took into account both the field operator’s corporate standards and EPC contractor requirements in terms of delivery conditions, composition and cost of solutions, and their integration.

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